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Electro-Deposition
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Background
Electrodeposition
A term for a broad range of industrial
processes which includes electrocoating,
e-coating, cathodic electrodeposition, and
electrophoretic coating, or lectrophoretic
painting. A characteristic feature of this
process is that colloidal particles
suspended in a liquid medium migrate
under the influence of an electric field
(electrophoresis) and are deposited onto
an electrode. All colloidal particles that
can be used to form stable suspensions
and that can carry a charge can be used in
electrophoretic deposition. This includes
materials such as polymers, pigments,
dyes, ceramics and metals.
The process is useful for applying
materials to any electrically conductive
surface. The materials which are being
deposited are the major determining
factor in the actual processing conditions
and equipment which may be used.
Anode
+
Cathode
<Cathode Reactions>
Electrolysis of water :
H2
2H2O + 2e-
+ 2OH-
Film deposition :
O2
H2
-NR2
-NR2H+ + OH-
+ H2O
A<Anode Reaction>
R+
Electrolysis of water :
4H+ + O2
2H2O
CH3COO-
+ H+
+ 4eCH3COOH
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History
Development of ED coating
1920
1939
Latex rubber electrodeposited on glove forms.
1959
First experiments on anodically electrodeposition paint
by Dr. George E. F. Brewer at the Ford Motor Company.
1963
First anodic electrocoating production facility, Ford Motor Co.
1971
Introduction of cathodic electrocoating technology to the automotive
and appliance industries.
1976
Introduction of high-film-build cathodic technology.
1939-Electrodeposition of emulsions on the inside of steel food
Containers.
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History
1st Gen.
1st Gen.
ED coating
2nd Gen.
Development
3rd Gen., Conventional
3rd Gen., High Functional
Generation
2nd (Not available)
1st (Not available)
3rd,
Conventional
(Available)
3rd, High-functional
(Available)
Main
Anionic, 1pack
Cationic, 1pack
2pack
Low bake type
Lead Free
High TP / High functional
Detail
1. Pb contains
2. Low film
build
1. Pb contains
2. Low film
build
1. Pb contains
2. Yellowing /
Non yellowing
3. High film build
1. Pb contains
2. Non yellowing
3. Medium film
build
1. Pb Free
2. Non yellowing
3. Medium film
build
1.
2.
3.
4.
Products
ED1600
ED1700
ED1800 / ED1900
ED2000
ED2100/ED2600
ED3000/ ED7000 / ECO
Application
HMC 1
HMC 1, 2
HMC 3,4,5,Asan,
DYKMC
HMC BUS
HMC5, BHMC,
ZAZ, JAC,
Izh-Avto
HMC1~4 ,51,Asan,Jeonju,
BHMC, DYKMC, HMI,
PK(Iran),Jeonju S/Frame
Chara
-cter
1980
1985
1990
1995
2000
2005
High Throw power
High Functional
Weatherability
Sn free available
2010
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Organization
KCC
1. Harmony with DuPont Europe & US ED technology
2. Optimization of domestic automotive technology
(Formulation / Process technology development)
3. Application of KCC technology & trouble shooting
DuPont
(Europe)
AQUA EC Technology
1984 ~ 2004
GLOBAL
E-COAT
SYSTEM
DuPont
(US)
ElectroShield, CorMax
Technology
2004 ~ 2022
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Organization
ED Dept. in Ulsan
1. Quality improvement of DuPont-KCC product
2. Manufacturing technology development
3. Co-Work with DuPont
4. Quality improvement of automotive plant
E-Coat
Organization
Central Research Institute
1. Establishment of KCC ED technology foundation
2. Development of high performance ED
( High throw power, weatherability)
3. Development of main binders and additives
Global sales & technical service Dept.
1. Technical service to Automotive plants
2. Support of coating facilities & factor control
3. Support of sales & technical development
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Customer list
Bath number : 14, Bath Capacity : 2,832ton
HMC Jeonju, Pilot 1,2
HMC 1, 2
: Accent, Click, Santafe, Avante
: Bus, Truck, Pilot models
HMC Asan
: Grandeur, Sonata
Domestic
In-Line
HMC 3
: Avante
HMC 51, 52
HMC 41, 42
: Genesis, Equus, Tusan
: Genesis coupe, Starex, Porter
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Customer list
Bath number : 16, Bath Capacity : 3,297ton
BHMC 1, 2
Pars Khodro,
Iran Khodro Diesel
Izh-Avto, ZAZ
DYKMC 1, 2
Overseas
In-Line
HMI, HMMR
China
JAC, GO(2 Lines)
DFML, SMT
HAOS
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Customer list
Bath number : 72, Bath Capacity : 1,475ton
Domestic
(Ulsan, Gyeongnam)
Overseas(excluding China)
8 Lines, 143 tons
Overseas(China)
11 Lines, 160 tons
Domestic
(Chungcheong, Gyeongin)
13 Lines, 213 tons
13 Lines, 392 tons
Part Line
Domestic
(Daegu, Pohang)
14 Lines, 151 tons
Domestic
(Jeonju, Gwangju)
8 Lines, 417 tons
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Sales
Unit : million won
80,000
67,587
70,315
67,731
77,770
Reason of sales increase
70,000
60,000
12,890
28,779
18,653
• Increase paint amount for HMC
25,424
50,000
overseas plant
• Extension to the new overseas
40,000
30,000
plants
54,697
51,663
42,307
20,000
-. Pars Khodro
48,991
-. HMMR
Export
수출
10,000
Domestic
내수
-
2007
2008
2009
-. ZAZ
-. Lots of Chinese plants
2010
• overall sales increase (15%↑ vs 2007)
• overseas sales increase (123% vs 2007)
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Promotion issues
IRAN
KHODRO
NISSAN
PROTON
NOW, KCC ED is
UNDER SUBMISSION
AVTO
VAZ
GAZ
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Commercialized Products
ED2100, ED2600, ED2800
ED3000
Commercialized
Products
ED3100, ED3500, ED3600, ED3700
ECO1000, ECO1200, ECO2000
ED7000-BLACK
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ED 2100 Series
Product
History
Feature
ED2100, ED2600, ED2800
1999 : HMC Asan plant
(The first Pb free ED paint at domestic automotive plant)
2000 : Application to the all HMC plants
2010 : HMC 5th plant, BHMC1st plant, ZAZ, Izh-Avto
-. Pb Free, Medium Build
-. Curing condition : 160℃
-. P/B : 0.25 ~ 0.35
-. Mixing Ratio 1 : 3.4(P/B 0.3)
-. PTA 52%, PTB 40%
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ED 3000 Series
Product
ED3000HT-GREY(M), ED3000HT-GREY(S)
History
2005 : HMC 2nd plant
(The first Sn Free ED paint at domestic automotive plant)
2006 : Application to the all HMC plants
2010 : HMC 1,2,3,41,42, Asan,
HAOS(Feed Over From PPG)
Feature
-.
-.
-.
-.
-.
High Throwing Power
Pb/Sn Free, Pb Free, Medium Build
Curing condition :160℃
P/B : 0.20 ~ 0.30, Mixing Ratio 1 : 4.5(P/B 0.25)
PTA 52%, PTB 36%
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ED 3000 Series
Application history
1. 2005.12.5
Application to the HMC
2nd plant
2. 2006.3
1) Feed Over
(~ 3 Turn over)
2) Tear Down
Application result
1. T/power improvement
1) Hood /Otr. Inr. :
50% improve
2) Cowl Comp :36% improve
3) S/Side : 44% improve
4) Wheel House Inr. Assy. :
81% improve
Tear Down
Wheel House Inner Assy’
S/Side Otr Inner
2. Appearance improvement
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ED3100,3500,3600,3700
Product
History
Feature
ED3100, ED3500, ED3600, ED3700
ED3100 :
ED3500 :
ED3600 :
ED3700 :
BHMC 2nd plant
HMI 2nd plant
DYKMC 1st, 2nd plant
Pars Khodro, Iran Khodro Diesel
-> Renault-Nissan CKD line
-. High Throw Power E-coat
-. Optimization to the overseas automotive plant facility condition
-. Pb Free, Pb/Sn Free(ED3700), Medium Build
-. Curing condition :160℃ or 165℃
-. P/B : 0.25, 0.3
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ECO1000 Series
Product
History
Feature
ECO1000, ECO1200, ECO2000
2007 :
2008 :
2009 :
2010 :
-.
-.
-.
-.
-.
HMC 51st plant
HMC BUS plant (Jeonju)
HMC TRUCK plant (Jeonju)
HMMR (Russia)
KCC Technology of ED paint
High Throwing Power
Pb Free, Medium Build
Curing condition : 160℃
P/B : 0.25
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ED7000-BLACK
Product
ED7000-BLACK
History
2006 : HMC Side Frame line (for truck)
High Weatherability (UV Durable)
Feature
-.
-.
-.
-.
-.
Pb Free, Medium Build Type
Curing condition :173℃
P/B : 0.15 ~ 0.25
Mixing Ratio 1 : 4.4(P/B 0.2)
PTA 44%, PTB 33%
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Technical Researches
• Compatibility for
ZrO2 pretreatment
* Ultra high T/Power
→ Consumption
reduction ≒ 20%
(Otr/inr=16/11㎛)
* Low bake off,
Low film density
① Improvement of
Throw Power ,
Mapping, Film build
② Improvement of
corrosion resistance
Major
Researches
* Pigment Zero
→ Dirt Zero,
Cost reduction
① ASH = 1~2%
② Film density = 1.2
* One component system
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Ultra High Throw Power E-Coat
Target
• Reduction of paint consumption through the Ultra
High throw power property
(Outer/Inner = 16/11㎛)
• Low bake off, Low film density
• Establishment of Throw Power Vs GA Gas pinhole Balance
Approach
• Good Appearance
• Corrosion resistance at low film (below 16㎛)
Plan
• Line simulation(2011), Mass production and application(2012)
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Ultra High Throw Power E-Coat
Current
E-coat
Ultra high throw
reduce exterior film build
Ultra high
Throw E-coat
Overall usage reduction
(15~20%)
film
substrate
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E-coat for Zirconium pretreatment
Zirconium
pretreatment
Approach
1. feature
• Shorten line length
(No use of surface conditioner)
• Reduction of sludge
• Free of heavy metals
• Operates at ambient temperature
3. Mapping Problem
Difficulty of controlling
appearance and DFT
2. Weaker Throw Power
Phospate PT
Zirconium PT
Exterior
20um
19um
Interior
11.5um
X
• Improvement of Throw Power & Appearance
• Control of film build
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Pigment Free E-Coat
• Extremely low Pigment
Target
• One component system
* ASH = 1~2%
* Film density = 1.2
• Bath Circulation reduce
Approach

Study and development with DuPont
• Eliminates setting and
Advantage
flocculation concerns
• Reduces operating cost
Resin
Bath
Filtration
Paste
• Increases UF flux rate
• Ultra-low VOC
Bath
Circulation
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Practical technical supporting
1
2
3
1,570배율
GA도금층
624배율
Submersible data
acquisition unit
Checking of rectifier
condition & real
coating voltage
during coating
at the ED bath
SEM +
Electron Probe
Micro Analyzer
Magnifying & analyzing
defect area of ED film
Focused Ion Beam
+SEM + EPMA
Magnifying & analyzing
defect area of ED film
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Practical technical supporting
4
5
Data pack for Oven
Temperature checking
Test Report for heavy
metal analysis
Oven condition check &
Real MPT check during
the oven drying process
Offer the test report
of heavy metals, PBBs,
PBDEs of KCC paint
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Test of bacteria,
yeast, fungi in the
ED process
Finds and removes a
factor
Trouble shooting
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Practical technical supporting
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8
9
Cyclic Corrosion Test
(approved by GM)
QUV, IR, ICP, GC, EPMA,
NMR, EDS, SEM..
Lots of analysis
instrument are available
Cyclic Corrosion
Test (approved by GM)
CCT for GM
ECC for Renault
And so on..
Salt Spray Test
Official institution
approved by KOLAS
Lots of analysis
Instrument is available
for customers
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